JP4224048B2 - Molded body manufacturing apparatus and manufacturing method - Google Patents

Description

  The present invention relates to a method and an apparatus for producing a molded body, and more specifically, a molded body having ultrafine processing, high dimensional accuracy, low residual stress, low birefringence, high light transmittance, and excellent mechanical strength. The present invention relates to an apparatus and a method for manufacturing a molded body that can be provided with a three-dimensional, thin, and large-area shape even in an ultra-low pressure molding process.

  Currently, a molded article having an ultra-fine irregular shape of several tens of nm to several hundred μm on the surface, and a three-dimensional, thin, and large-area shape is an optical component for electronic displays such as a microlens array, There is a demand for optical information communication components such as multimode optical waveguides, life science components such as microchemical chips, and the like.

  The following is the prior art of the manufacturing method of the molded article which has such a fine uneven part on the surface.

  Patent Document 1 aims to provide a method for efficiently producing a thin and large optical molded article having excellent light transmittance, low birefringence, and mechanical strength characteristics, and having fine irregularities. The lower die of a press molding machine comprising an upper die and a lower die provided with a fine unevenness having a height or depth of less than 50 μm on the cavity surface of at least one die and provided at a distance. The molten halogen-free thermoplastic resin is supplied, and the molten resin is pressed while the temperature of the molten resin is in the temperature range of (Tg + 10 ° C.) or more and less than (Tg + 150 ° C.) with respect to the glass transition temperature (Tg) of the resin. A method for producing an optical molded body is disclosed.

  Patent Document 2 accurately forms a fine concavo-convex pattern, eliminates non-uniform filling of resin, improves releasability, eliminates temperature unevenness of the product at the time of demolding, and has a large area and thin molding without warping. For the purpose of providing a production method suitable for obtaining a body, a molten alicyclic structure is formed in a cavity formed by a movable mold whose inner surface is coated with diamond-like carbon and a fixed mold. A method for producing a molded body is disclosed, which comprises filling a containing polymer resin and then compressing the molten resin with a movable mold.

  Patent Document 3 discloses a base material prepared with a mold having a transfer surface on which a concavo-convex pattern is formed and softened by heating to a specific temperature for the purpose of providing a method for efficiently and accurately transferring a fine shape. In addition, a fine shape transfer method is disclosed in which, after pressing and pressing the transfer surface, the mold is forcibly separated from the base material at a specific temperature, and the reverse pattern of the concave-convex pattern is transferred to the surface of the base material. Has been.

  In Patent Document 4, for the purpose of providing an optical article having an optical element such as a fine Fresnel lens, a lenticular lens, or a prism lens with high quality and at a low cost, a fine uneven shape of a mold is formed using a slit nozzle. An optical article manufacturing method including a step of coating and forming a radiation curable resin liquid on the entire surface is disclosed.

In Patent Document 5, a fine concavo-convex pattern is provided for the purpose of providing a fine pattern transfer processing method capable of forming a fine concavo-convex pattern including a light wavelength or less, which is inexpensive and mass-produced, on a transfer target. The transfer body is prepared, the material to be transferred is melted by heating, poured onto the uneven pattern of the transfer body, and then cooled to solidify the material to be transferred and the unevenness A fine pattern transfer processing method is disclosed in which a pattern is transferred, then separated from the transfer body and taken out as a transfer target.
Japanese Patent Laid-Open No. 2003-21475 JP 2004-98580 A JP 2001-26052 A JP 2002-268146 A JP 2000-39702 A

  However, in the above prior art, defects such as optical distortion and warpage of the molded body, dimensional change of the fine uneven pattern due to heat shrinkage, etc. occur (Patent Document 1), and high pressure is required for the press (Patent Document). 1, 2, 5), unsuitable for the manufacture of molded products with a three-dimensional thin-walled large area (Patent Documents 2 and 3), and the occurrence of defective products due to scattering of resin liquid (Patent Document 4) There is a point.

  Therefore, the object of the present invention is to form a molded body having ultrafine processing, high dimensional accuracy, low residual stress, low birefringence, high light transmittance, and excellent mechanical strength, even in an ultra-low pressure molding process, in a three-dimensional manner. Another object of the present invention is to provide a manufacturing apparatus and a manufacturing method of a molded body that can be provided with a thin and large-area shape.

The invention according to claim 1 is a resin melting portion that melts and transports a thermoplastic resin, a resin delivery portion that is connected to the resin melting portion, and that feeds the molten resin flowing in a specified amount, and the resin A discharge unit that applies the molten resin delivered from the delivery unit to the surface to be coated from above, a high-rigidity guide that supports the discharge unit, and a pair of molds that are arranged to face each other,
The resin delivery part is a storage cylinder that delivers a specified amount after temporarily storing the molten resin that has flowed in,
The storage cylinder includes a cylinder that stores molten resin, and a piston that is provided in the cylinder and that pushes out and sends out the molten resin in a specified amount, and the molten resin is interposed between the cylinder and the piston. There is a gap that can pass through,
The application surface of the molten resin is at least a part of a lower mold in the pair of molds,
The molten resin is applied to the application surface of the lower mold in a shape and thickness substantially close to the final product while moving the tip lip portion of the discharge part along the shape of the application surface of the lower mold. And
Here, the discharge unit moves while being supported by a high-rigidity guide so as not to bend in the vertical direction due to the reaction of the application of the molten resin, and applies the molten resin,
Then, an apparatus for producing a formed feature that Ru obtain a molded body by pressure of molds,
A valve for opening and closing the connection channel is provided in the connection channel between the resin melting part and the resin delivery part; and
Further provided is a moving means for moving the application surface of the lower mold in the vertical direction so that the distance between the tip of the discharge part for applying the molten resin and the application surface of the lower mold can be adjusted. It is the manufacturing apparatus of the molded object characterized by becoming .
The invention according to claim 2 is an apparatus for manufacturing a molded body according to claim 1, wherein the manufacturing apparatus is used for manufacturing a molded body having a thickness in a range of 50 μm to 5 mm. is there.
According to a third aspect of the present invention, the storage cylinder includes a cylinder that stores the molten resin, a piston that is provided in the cylinder and pushes out the molten resin by a specified amount, and a piston drive that moves the piston back and forth. A gap portion through which the molten resin can pass is provided between the cylinder and the piston, and the piston is moved backward by the piston driving means together with the inflow of the molten resin from the resin melting portion. 3. A structure according to claim 1, wherein a predetermined amount of molten resin is gradually stored from the tip of the cylinder, and then the piston is advanced to deliver a prescribed amount of molten resin. It is a manufacturing apparatus of the described molded object.
According to a fourth aspect of the present invention, the storage cylinder includes a cylinder that stores the molten resin, a piston that is provided in the cylinder and pushes out the molten resin by a specified amount, and a piston drive that moves the piston back and forth. A gap portion through which the molten resin can pass is provided between the cylinder and the piston, and the piston is moved backward by the piston driving means to a place where a predetermined amount of the molten resin can be stored, Subsequently, after a molten resin is caused to flow from the resin melting portion and a predetermined amount of the molten resin is gradually stored from the tip of the cylinder in the storage cylinder, the piston is advanced to deliver a specified amount of the molten resin. It is comprised so that it may be, It is a manufacturing apparatus of the molded object of Claim 1 or 2 characterized by the above-mentioned.
In the invention according to claim 5 , both sides of the discharge part are supported by at least two high-rigidity guides provided along the application direction of the molten resin, and the high-rigidity guides are formed of the molten resin. 5. The molded body manufacturing apparatus according to claim 1 , wherein the molded body manufacturing apparatus is fixed by two or more high-rigidity guide support members respectively provided on the upstream side and the downstream side in the coating direction. is there.
According to a sixth aspect of the present invention, the manufacturing apparatus includes the resin melting portion, the resin delivery portion, a discharge portion, a mold, and a bed on which these are mounted, and the discharge portion is a discharge portion support member. The support is supported by at least one high-rigidity guide provided along the application direction of the molten resin, and the high-rigidity guide is fixed to the bed . 4. A manufacturing apparatus for a molded article according to any one of 4 above.
According to a seventh aspect of the present invention, the moving means is a press mold plate for placing the lower mold and pressurizing the two molds. an apparatus for manufacturing a molded body according to claim 1, wherein the distance between the tip the coated surface of the lower tool is adjusted.
According to an eighth aspect of the present invention, the moving means moves up and down provided between the lower mold and a press mold plate for placing the lower mold and pressurizing both molds. 2. The molded body manufacturing apparatus according to claim 1 , wherein the distance between the tip of the discharge unit and the application surface of the lower mold is adjusted by the vertical movement of the vertical movement stage. It is.
The invention according to claim 9 is configured such that a molding die is placed on a lower die, the molding die is the surface to be coated, and the lower die and the molding die are separable, and only the molding die is provided. The apparatus according to claim 1 , wherein the distance between the tip end portion of the discharge portion and the surface to be coated on the lower mold is adjusted.
The invention according to claim 10, a method for producing a molded article using the manufacturing apparatus of the shaped body following the steps of (1) heating at least one of the pair of molds, (2) A step of melting the thermoplastic resin in the resin melting portion; (3) a step of allowing the obtained molten resin to flow into the resin delivery portion and storing; and (4) a specified amount of the molten resin stored in the resin delivery portion. And (5) while moving the tip lip portion of the discharge part along the shape of the application surface of the lower mold, the supplied molten resin to the application surface of the lower mold, A step of applying a shape and a thickness substantially close to the final product; and (6) a step of pressing the applied resin to cool and solidify it while adjusting the shape of the resin,
The resin delivery unit is a storage cylinder that temporarily stores the molten resin that has flowed in and then delivers the molten resin in a specified amount, and the storage cylinder is provided in the cylinder, and is provided in the cylinder and defines the molten resin. A piston that pushes out in an amount, and a gap portion through which the molten resin can pass is provided between the cylinder and the piston,
In the method for manufacturing a molded body, the discharge unit moves while being supported by a high-rigidity guide so as not to bend in the vertical direction due to a reaction of the application of the molten resin. is there.
Manufacturing equipment:
A resin melting part that melts and transports a thermoplastic resin, a resin sending part that is connected to the resin melting part, sends a molten resin that flows in a specified amount, and a molten resin sent from the resin sending part. A discharge part that is applied to the surface to be coated from above, a high-rigidity guide that supports the discharge part, and a pair of molds that are arranged to face each other,
The resin delivery part is a storage cylinder that delivers a specified amount after temporarily storing the molten resin that has flowed in,
The storage cylinder includes a cylinder that stores molten resin, and a piston that is provided in the cylinder and that pushes out and sends out the molten resin in a specified amount, and the molten resin is interposed between the cylinder and the piston. There is a gap that can pass through,
The application surface of the molten resin is at least one part of the lower mold in the pair of molds, and the tip lip portion of the discharge part is moved along the shape of the application surface of the lower mold, Applying the molten resin to the application surface of the lower mold in a shape and thickness almost close to the final product,
Here, the discharge part does not bend in the vertical direction due to the reaction of the application of the molten resin.
In addition, the molten resin is applied while being supported by a high-rigidity guide,
Thereafter, a molded body manufacturing apparatus characterized in that a molded body is obtained by pressing both molds.
According to an eleventh aspect of the present invention, the storage cylinder includes a cylinder that stores the molten resin, a piston that is provided in the cylinder and that pushes out the molten resin by a specified amount, and a piston drive that moves the piston back and forth. And a gap portion through which the molten resin can pass is provided between the cylinder and the piston. In the step (3), the piston drive is performed together with the inflow of the molten resin from the resin melting portion. The piston is moved backward by means, and a predetermined amount of molten resin is gradually stored from the tip of the cylinder, and then in the step (4), the piston is moved forward to deliver a specified amount of molten resin. It is a manufacturing method of the molded object according to claim 10 characterized by things.
According to a twelfth aspect of the present invention, the storage cylinder includes a cylinder that stores the molten resin, a piston that is provided in the cylinder and that pushes out the molten resin by a specified amount, and a piston drive that moves the piston back and forth. A gap portion through which the molten resin can pass is provided between the cylinder and the piston, and in the step (3), the piston driving means to a place where a predetermined amount of the molten resin can be stored. In the step (4), the piston is moved backward by the above, and then a molten resin is caused to flow from the resin melting portion to gradually store a predetermined amount of the molten resin in the storage cylinder from the tip portion of the cylinder. the method of manufacturing a molded article according to claim 10, characterized in that the molten resin of specified amount by advancing the piston is configured to be delivered A.
In a thirteenth aspect of the present invention, a valve that opens and closes the connection flow path is provided in a connection flow path between the resin melting portion and the resin delivery portion, and the storage of the molten resin is completed in the step (3). The method for manufacturing a molded body according to any one of claims 11 to 12 , wherein the valve is closed at a point in time.
The invention according to claim 14 is the molded article according to any one of claims 11 to 13 , wherein in the step (5), the thickness of the molten resin applied to the surface to be coated is 50 μm to 5 mm. It is a manufacturing method.

  According to the present invention, a molded body having ultra-fine processing, high dimensional accuracy, low residual stress, low birefringence, high light transmission, and excellent mechanical strength can be obtained in three dimensions, even in an ultra-low pressure molding process. It is possible to provide a manufacturing apparatus and a manufacturing method of a molded body that can be provided with a thin-walled and large-area shape.

Hereinafter, the present invention will be described in more detail with reference to the drawings.
FIG. 1 is a schematic cross-sectional view for explaining the production apparatus of the present invention.
In FIG. 1, a manufacturing apparatus 1 of the present invention includes a resin melting part 10 that melts and transports a thermoplastic resin, and a resin delivery part that is connected to the resin melting part 10 and delivers a molten resin that flows in a specified amount. 11 and a discharge part 12 for applying the molten resin delivered from the resin delivery part 11 onto the surface to be coated from above. The manufacturing apparatus 1 according to the present invention further includes a pair of an upper mold 131 and a lower mold 132 that are arranged to face each other, and at least a part of the surface of the lower mold 132 is made of a molten resin. In the manufacturing process of the molded body that forms the surface to be coated, the molten resin is applied to the surface to be coated of the lower mold 132 while moving the discharge part 12 in the direction of the arrow, for example, and then both the molds 131 and 132 are added. A compact can be obtained by pressure.

  As the resin melting section 10, an extruder known in the art can be used, and as such an extruder is well known, a cylinder 101 and a screw 102 for plasticizing and melting a solid resin are known. A screw rotating mechanism 103 for rotating the screw 102, a hopper 104 for introducing solid resin into the cylinder 101, and a heater 1011 as a heating means on the outer peripheral portion of the cylinder 101. Has no cooling means.

According to an embodiment of the present invention, the resin delivery unit 11 is preferably a storage cylinder that temporarily stores the molten resin that has flowed in and then delivers the resin in a specified amount.
FIG. 2 is a schematic cross-sectional view for explaining a storage cylinder used in the present invention.
In FIG. 2, a storage cylinder 110 has a cylindrical shape as a whole, a cylinder 1101 that stores molten resin, a piston 1102 that is provided in the cylinder 1101 and that pushes and sends out a molten resin in a specified amount, and moves the piston back and forth. Piston drive means 1103. The storage cylinder 110 has a heater 1107 as a heating means on the outer peripheral portion, and has a cooling means (not shown) as necessary. As shown in FIG. 2, a gap 1104 through which the molten resin can pass is provided between the cylinder 1101 and the piston 1102, and when the molten resin flows from the resin melting portion 10 through the inlet 1105, The molten resin flows in the direction of the arrow through the gap 1104. By setting the flow rate of the molten resin faster, the molten resin can be prevented from staying. The size of the gap 1104 is such that the flow rate of the molten resin passing through is made as fast as possible, and at the same time, the molten resin does not stay there, and when the molten resin is allowed to flow in, an excessive pressure load is not applied to the molten resin portion 10. What is necessary is just to determine suitably, For example, it is about several mm, specifically 0.5-5 mm.
As the molten resin flows in, the piston driving means 1103 is operated to move the piston 1102 backward as shown in FIG. By this operation, the molten resin is gradually stored from the front end portion (discharge portion side) of the cylinder 1101. Separately from this, the piston 1102 is moved backward by the piston driving means 1103 to a place where a predetermined amount of molten resin can be stored, and then the molten resin is caused to flow from the resin melting portion 10 so that the predetermined amount of molten resin is introduced into the cylinder 1101. You may make it accumulate gradually from a part. When the storage of the molten resin is completed with the specified amount, the piston driving means 1103 is operated, the piston 1102 is advanced by a predetermined distance, and the specified amount of the molten resin can be delivered. The position control accuracy of the piston 1102 is required to be relatively high. Therefore, it is preferable to use a means using a mechanism that easily ensures accuracy, such as a method of combining a servo motor and a ball screw, as the piston driving means 1103.

According to such a configuration, the molten resin that has flowed in first is first sent to the discharge portion and applied. Therefore, thermal deterioration due to a long residence time of the molten resin (transparent resin is yellowed (discolored) or browned (black spot)) is prevented. Furthermore, even when the resin melting part 10 and the storage cylinder 110 are connected by a short flow path, the residence time of the molten resin is shortened, and the problem of thermal degradation is further prevented. In addition, when a molded body is manufactured using a molten resin that has undergone thermal degradation, for example, when the usage of the molded body is an optical product, desired light transmittance, refractive index, and the like may not be obtained.
If the gap 1104 through which the molten resin can pass is not provided, the cylinder 1101 and the piston 1102 are in contact with each other, and metal powder is generated due to friction between both metals, which may adversely affect the product. In the storage cylinder 110, a gap 1104 is provided between the cylinder 1101 and the piston 1102, and thus such metal powder is not generated.

  As shown in FIGS. 2 to 3, the molten resin that first flows into the cylinder 1101 does not enter the storage cylinder 110 in the direction opposite to the tip of the cylinder 1101 (on the piston driving means 1103 side). A backflow prevention unit 1106 that does not allow the molten resin to pass therethrough is provided. The backflow prevention unit 1106 forms a curved surface from the molten resin inflow port 1105 toward the tip of the cylinder 1101 so that the molten resin can be easily guided to the tip of the cylinder 1101.

Further, according to the present invention, it is preferable to provide a valve for opening and closing the connection channel in the connection channel between the resin melting part 10 and the storage cylinder 110.
FIG. 4 is a schematic cross-sectional view of a manufacturing apparatus for explaining a form in which a valve is provided in a connecting flow path between the resin melting part 10 and the storage cylinder 110. The manufacturing apparatus of FIG. 4 has substantially the same configuration as that of FIG. 1 except that a valve 15 is provided in the connection flow path 14 between the resin melting part 10 and the storage cylinder 110. As described above, after the storage of the molten resin in the cylinder 1101 of the storage cylinder 110 is completed, the piston driving unit 1103 is operated, the piston 1102 is advanced by a predetermined distance, and a specified amount of the molten resin is sent to the discharge unit 12. However, the amount of molten resin delivered is determined by the volume of the molded body. Therefore, in order to manufacture the molded body with high accuracy, it is necessary to store the molten resin in the cylinder 1101 with a controlled amount and to send the molten resin. However, if a pressure difference occurs between the molten resin portion 10 and the storage cylinder 110 after the molten resin is stored (the molten resin pressure of the molten resin portion 10 is usually increased), the molten resin in the molten resin portion 10 is more than necessary. It flows in, exceeds the specified amount, and the amount of molten resin stored becomes excessive, making it impossible to manufacture a molded body with high accuracy. Therefore, a valve 15 is provided in the connecting flow path 14 between the resin melting part 10 and the storage cylinder 110, and the valve 15 is closed when storage of the molten resin in the cylinder 1101 is completed, and the molten resin from the resin melting part 10 is closed. Block inflow. As a result, a specified amount of molten resin can be stored.
Furthermore, after the molten resin storage is completed, the piston driving means 1103 is operated, the piston 1102 is moved forward by a predetermined distance, and a prescribed amount of molten resin is sent to the discharge unit 12. At this time, the valve 15 is closed. It is preferable to leave. By closing the valve 15, it is possible to prevent the molten resin delivery pressure due to the advancement of the piston 1102 from escaping to the resin melting portion 10 via the connection channel 14. Thereby, a specified amount of molten resin is sent to the discharge part 12, and as a result, a molded object can be manufactured accurately.

  The valve 15 is not particularly limited as long as it can block the molten resin flow path (connection flow path 14) and control the inflow / outflow of the molten resin. For example, a known rotary valve can be used.

  In the present invention, the discharge unit 12 for discharging the molten resin delivered from the resin delivery unit 11 onto the coated surface from above or coating the coated surface of the mold is not particularly limited. A film that is deformed into a film and discharged is preferable. Usually, the discharge part 12 is directly connected to the resin delivery part 11.

In the above description, the resin delivery unit 11 has been described using the storage cylinder 110 that temporarily stores the molten resin that has flowed in and then delivers the resin in a specified amount. However, the present invention is not limited to this configuration. For example, a cylinder having an injection function can be used as the resin delivery unit 11 instead of the storage cylinder 110.
FIG. 5 is a schematic cross-sectional view for explaining another form of the manufacturing apparatus of the present invention using a cylinder having an injection function as a resin delivery section.
The manufacturing apparatus 2 of the present invention shown in FIG. 5 is similar to FIG. 1, and is connected to the resin melting part 10 for melting and transporting the thermoplastic resin, and connected to the resin melting part 10, and defines the inflowing molten resin. It is mainly composed of a resin delivery part 11 that delivers in a quantity and a discharge part 12 that applies the molten resin delivered from the resin delivery part 11 onto the surface to be coated from above. The manufacturing apparatus 2 of this embodiment uses a cylinder 111 having an injection function as a resin delivery unit. As the cylinder 111, a cylinder for an injection molding machine can be used. For example, the cylinder 111 has a cylindrical shape and has a through-hole 1112 in which a screw 1111 is provided. Has a plurality of heaters 1114 and is fitted with cooling means (not shown) as required. The screw 1111 is configured to be driven to rotate and to move back and forth by the driving means 1113.
Molten resin from the resin melting part 10 flows in through the connection flow path 14 and is sent toward the tip of the cylinder 111 by the rotation of the screw 1111. After a predetermined amount of molten resin is stored at the tip, the screw 1111 is advanced, and a specified amount of molten resin is delivered to the discharge unit 12. As in the embodiment shown in FIG. 4, a valve 15 is provided in the connection flow path 14 between the resin melting portion 10 and the cylinder 111, and the valve 15 is closed when the molten resin is stored in the cylinder 111. It is preferable to block the inflow of the molten resin from the resin melting part 10. In addition, after the storage of the molten resin is completed, a prescribed amount of the molten resin is sent to the discharge unit 12 by the injection function of the cylinder 111, and it is preferable that the valve 15 is also closed at this time. Thereby, similarly to the case of the storage cylinder, a predetermined amount of the molten resin can be delivered, and a molded body can be manufactured with high accuracy.

Furthermore, the manufacturing apparatus of the present invention, unlike the embodiment described above, has a resin delivery part having a function of melting a thermoplastic resin and an injection function of injecting a molten resin in a specified amount, and a melt delivered from the resin delivery part. It may be provided with a discharge unit that applies the resin from above while moving the resin to the surface to be applied.
FIG. 6 is a schematic cross-sectional view for explaining such a manufacturing apparatus according to another embodiment of the present invention.
In FIG. 6, the manufacturing apparatus 3 of the present invention includes a resin delivery unit 21 having a function of melting a thermoplastic resin and an injection function of injecting the molten resin in a specified amount, and a molten resin delivered from the resin delivery unit 21. It is mainly comprised from the discharge part 12 apply | coated to a coating surface from upper direction. The manufacturing apparatus 3 of the present embodiment can use a cylinder for an injection molding machine as the resin delivery unit 21. For example, the cylinder has a through-hole 212 in which the overall shape is cylindrical and the screw 211 is provided. The cylinder has a plurality of heaters 215 on the outer peripheral surface of the cylinder, and a cooling means (not shown) is mounted as necessary. The screw 211 is configured to be rotated and driven in the front-rear direction by the driving means 213.
When the solid resin is introduced from the hopper 214, the solid resin is sent in the direction of the tip portion by the rotation of the screw 211 in the cylinder. At this time, since the cylinder is heated by the heater 215, the heat transfer from the cylinder and the screw 211 are performed. The solid resin is melted by the shear heat generated by the rotation of. After a predetermined amount of molten resin is stored at the tip, the screw 211 is moved forward, and a prescribed amount of molten resin is delivered to the discharge unit 12.
Furthermore, the manufacturing apparatus of the present invention may use an extruder instead of the resin delivery part 21 having the function of melting the thermoplastic resin and the injection function of injecting the molten resin in a specified amount in the form of FIG. it can. As is well known, an extruder is provided with a cylinder, a screw inside the cylinder, and drive means for rotationally driving the screw. In this case, the molten resin can be delivered by adjusting the delivery amount of the molten resin, that is, the discharge amount from the discharge portion, according to the number of rotations per unit time of the screw, and determining the total discharge amount based on the rotation time.

Next, the process of manufacturing a molded body using the manufacturing apparatus of the present invention will be described.
The method for producing a molded body of the present invention includes (1) a step of raising the temperature of at least one of the pair of molds, (2) a step of melting a thermoplastic resin in the resin melting portion, and (3) obtained. A step of causing the molten resin to flow into the resin delivery section and storing it; (4) a step of delivering the molten resin stored in the resin delivery section in a specified amount; and (5) using the discharge section to deliver the delivered molten resin. A step of coating the coated surface of the lower mold from above and coating the coated surface; and (6) a step of pressing the coated resin to cool and solidify it while adjusting the shape of the resin.
In addition, although the following description has illustrated the form using the storage cylinder which sends out the molten resin which flowed in once as a resin delivery part, after having stored temporarily, as shown in FIGS. 1-4, this invention Is not limited to the following examples.

The step (1) will be described below.
Next, in the step (2), solid resin is introduced into the resin melting portion 10 from the hopper 104 into the cylinder 101, and the solid resin is melted by heating of the outer peripheral portion of the cylinder 101 and shearing heat due to rotation of the screw 102.
The solid resin is not particularly limited. PI), polystyrene (PS), polypropylene (PP), polyamide (PA), polyethylene (PE), polyacetal (POM), ethylene-vinyl acetate copolymer resin (EVA), acrylonitrile butadiene styrene (ABS), polyvinyl chloride ( PVC), polyphenylene oxide (PPO) or a mixture thereof. Further, a thermoplastic resin specially manufactured in accordance with the performance required for the molded body may be used. For thermoplastic resins, various fillers such as glass fiber and carbon, heat stabilizer, weather stabilizer, antistatic agent, slip agent, antiblocking agent, antifogging agent, lubricant, dye, pigment, Various known additives such as natural oils, synthetic oils and waxes can also be blended.

  Next, in the step (3), the molten resin is caused to flow into the storage cylinder 110 through the connection channel 14. The storage cylinder 110 is provided with a gap 1104 through which molten resin can pass between the cylinder 1101 and the piston 1102. When the molten resin flows from the resin melting part 10 through the inlet 1105, this gap 1104 is provided. The molten resin flows in the direction of the arrow through the portion 1104. The piston 1102 is moved backward by the piston driving means 1103 together with the inflow of the molten resin from the resin melting section 10, and a predetermined amount of the molten resin is gradually stored from the tip of the cylinder 1101. As described above, after the storage is completed, it is preferable to close the valve 15 and block the inflow of the molten resin from the resin melting portion 10 as shown in FIG.

  Subsequently, in step (4), the molten resin stored in the storage cylinder 110 is delivered to the discharge unit 12 in a specified amount. The molten resin is delivered by advancing the piston 1102 by a predetermined distance by the operation of the piston driving means 1103. As the piston 1102 moves forward, the molten resin that has flowed in first is first delivered to the discharge unit 12 and applied, and thermal deterioration due to a long residence time of the molten resin is prevented. When the molten resin is delivered, it is preferable that the valve 15 is closed to prevent the molten resin delivery pressure due to the advancement of the piston 1102 from escaping to the resin melting portion 10 via the connection channel 14.

Next, in the step (5), the molten resin is applied to the surface to be coated from above using the discharge unit 12.
In the present invention, the application surface of the molten resin is at least one part of the lower mold in the pair of molds arranged to face each other, and after applying the molten resin to the lower mold while moving the discharge unit 12 It is preferable to obtain a molded body by pressing both molds. That is, as shown in FIG. 1, the manufacturing apparatus 1 of the present invention further includes a pair of an upper mold 131 and a lower mold 132 that are arranged to face each other, and the surface of at least a part of the lower mold 132 is melted. After forming the resin application surface and applying the molten resin to the application surface of the lower mold 132 while moving the discharge part 12 in the direction of the arrow, the molded body is pressed by pressing both molds 131 and 132. It is preferable to obtain.
The step (6) will be described below.

The coated surface of the lower mold 132 can be a molding mold that is placed on the lower mold 132 and has fine uneven portions on the surface.
FIG. 7A is a plan view of the mold 81 placed on the lower mold 132, and FIG. 7B is a front view. In the form of FIG. 7, the molten resin is applied once in the direction of the arrow 82 in FIG. 7A using a discharge unit that can discharge the molten resin onto the film. Further, as a part of the mold 81, a stamper 83 having fine uneven portions on the surface was used, and this was installed on the surface of the convex portion of the mold 81. The mold 81 and the stamper 83 are heated so that the molten resin adheres to the fine uneven portions. In FIG. 7B, the thermoplastic resin melted on the coated surface of the lower mold 132 while moving the tip lip portion 84 of the discharge portion in the direction of the arrow 82 and along the shapes of the molding die 81 and the stamper 83. 85 is applied to a shape and thickness almost similar to the final product. Subsequently, in FIG. 7C, the applied thermoplastic resin is pressed by the cooperation of the upper mold 131 and the lower mold 132, and the shape of the molded body is adjusted. Next, in FIG.7 (d), the said thermoplastic resin is cooled and solidified, applying a press force, a metal mold | die is opened, and the molded object 86 is taken out.

Here, according to the present invention, in the step of FIG. 7 (b), the discharge portion moves while being supported by the high-rigidity guide so as not to bend in the vertical direction due to the reaction of the application of the molten resin. It is preferable to apply.
FIG. 8 is a diagram for explaining a process of applying a molten resin from a discharge unit that moves while being supported by a high-rigidity guide.
In FIG. 8A, both sides of the discharge unit 12 are supported by at least two high-rigidity guides 91 and 92 provided along the application direction of the molten resin, and the high-rigidity guides 91 and 92 are the molten resin. Are fixed by two or more support members 93 and 94 provided respectively upstream and downstream in the coating direction. When applying the molten resin from the discharge portion, the discharge portion 12 moves in the direction of the arrow along the high-rigidity guides 91 and 92 as shown in FIG. Thus, the molten resin can be applied to the set thickness without being bent in the vertical direction due to a reaction when the discharge unit 12 applies the molten resin to the application surface of the mold.
The high-rigidity guides 91 and 92 may be made of any material as long as the discharge part 12 does not bend in the vertical direction due to the reaction of the application of the molten resin. For example, a guide made of stainless steel can be used. .

  Moreover, FIG.8 (b) is a figure explaining another form using a highly rigid guide (a top view, a side view, and a front view are included). In this embodiment, the manufacturing apparatus of the present invention includes the resin melting portion, the resin delivery portion, the discharge portion, and the mold as described above, and a bed on which these are mounted (in FIG. 8B, the discharge portion, Only the bed, the rigid guide and the support member are shown). In FIG. 8B, the discharge unit 12 is supported by at least one high-rigidity guide 911 provided along the application direction of the molten resin via two support members 931 and 941. In the form of FIG. 8B, one high-rigidity guide 911 has the shape of a guide rail provided with a bearing, and the support members 931 and 941 and the discharge unit 12 move along the application direction on the guide rail. It has become. The high-rigidity guide 911 is fixed on the bed 950. Furthermore, in order to further increase the rigidity when the molten resin is applied onto the coated surface of the mold, it is preferable that the support of the discharge unit 12 be further closer to the coated surface, and a high-rigidity guide is placed on the mold. It may be fixed to the pressed mold platen. When applying the molten resin from the discharge portion, the discharge portion 12 moves in the direction of the arrow along the high-rigidity guide 911 as shown in FIG. Thereby, the discharge part 12 does not bend in the vertical direction due to the reaction of the application of the molten resin, and the molten resin can be applied to the set thickness.

  In the form shown in FIG. 7, the mold 81 has a convex portion, and a stamper 83 having a fine irregular portion is provided on the surface of the convex portion. Therefore, in order to move the tip lip 84 of the discharge part along the shapes of the molding die 81 and the stamper 83, a moving means for moving the lower mold in the vertical direction is provided, and the tip lip 84 and the stamper 83 of the discharge part are provided. It is preferable to adjust the distance. Compared to a large-scale device configuration that moves the discharge part, resin melting part, and resin delivery part in the vertical direction, this form allows the mold to play a role of vertical movement, enabling rapid vertical movement. As a result, the moving speed of the discharge unit can be increased, and the productivity can be increased.

Specifically, as shown in FIG. 9, by installing the lower mold 132 and using the press mold 100 having a pressurizing function of a pair of molds as moving means, moving the press mold 100 up and down, There is a method in which the distance between the tip lip portion 84 of the discharge portion and the stamper 83 is adjusted.
Further, as shown in FIG. 10, a vertical movement stage 1001 is provided between the press mold platen 100 and the lower mold 132 as moving means, and the vertical movement stage 1001 moves the vertical movement stage 1001 to the tip lip 84 of the discharge unit. There is a method in which the distance of the stamper 83 is adjusted.
Furthermore, as shown in FIG. 11, the lower mold 132 and the mold 81 are configured to be separable, and only the mold is moved up and down, and by this vertical movement, the tip lip portion 84 of the discharge portion, the stamper and the stamper are moved. The method of adjusting the distance of 83 is mentioned.
The moving means may be performed using various actuators. By the said form, molten resin can be apply | coated on the stamper 83 in a three-dimensional shape, and the application | coating thickness of the molten resin to the stamper 83 can be changed easily.

A particularly suitable method for producing the molded article of the present invention includes the following series of steps (a) to (i).
(a) As shown in FIG. 7, two molds of an upper mold 131 and a lower mold 132 are prepared. Then, the temperature of the cavity surface of the upper mold 131 is set so that the solidified layer is not formed on the surface layer of the molten resin 85 in contact with the cavity surface of the upper mold 131 in the pressing step, and the applied pressing force is The temperature is raised to a temperature at which a softened state capable of being deformed to the shape of the cavity surface of the upper mold 131 can be maintained. In addition, the temperature of the cavity surface of the lower mold 132 is raised to a temperature at which the molten resin 85 adheres to the fine irregularities (mold raising step);
(b) After the temperature rise of the mold is completed, application is performed while moving the lip portion 84 so that the molten resin 85 is filled from the tip lip portion 84 of the discharge portion to the entire fine uneven portion, and Application is performed to a shape that is almost close to the final shape of the molded body. The thickness of the molten resin 85 is preferably 50 μm to 3 mm (application process);
(c) After the coating process is completed, the upper mold 131 and the lower mold 132 are fitted together, and the melt that exists between the cavity surface of the upper mold 131 and the cavity surface of the lower mold 132 by the force generator Pressing the resin 85 to adjust the shape of the resin to the shape of the closed space formed between the closed cavities (pressing process);
(d) Cooling and solidifying the thermoplastic resin to a desired temperature while applying a pressing force in order to compensate for shrinkage due to cooling of the molten resin 85 (solidification step);
(e) After completion of the solidification process, a small amount of the upper mold 131 and the lower mold 132 are opened within the fitted range (mold loosening process);
(f) Peeling means (not shown) mounted on the mold, either between the cavity surface of the upper mold 131 and the molded body or between the cavity surface of the lower mold 132 and the molded body. ) To separate the cavity surface and the molded body (first peeling step);
(g) The cavity surface and the molded body are peeled off by a peeling means mounted on the mold on the peeling surface opposite to the step (f) (second peeling step);
(h) Open the mold to the extent that the molded body can be removed (mold opening process); and
(i) The molded body is taken out of the mold (molded body removing step).

  In the step (a), the temperature of the cavity surface of the lower mold, “the temperature at which the thermoplastic resin discharged in the coating step adheres to the fine irregularities” is the surface property (surface roughness of the mold 81). Etc.), material (material, presence / absence of release agent treatment, etc.), resin type and temperature, movement speed (application speed) of the tip lip 84 of the discharge part, and the like.

  In the step (b), since the molten resin 85 generally has a certain viscosity even in a molten state (for example, 1000 Pa · s or more) unlike a liquid ultraviolet curable resin, for example, molding is performed. Application can be performed to a shape that is approximately close to the final shape of the body. In the embodiment of FIG. 7, the resin is applied once from the tip lip portion 84 of the discharge portion. However, the present invention is not limited to this, and the application is performed while reciprocating the tip lip portion 84 of the discharge portion a plurality of times. May be performed.

  In the step (c), the pressing pressure can be 10 MPa or less. Therefore, even if the force generator is small, a large area product can be manufactured. Moreover, it leads to size reduction, space saving, energy saving, and cost reduction of the apparatus. In addition, since the resin in the cavity hardly flows during pressing, a phenomenon that causes optical distortion and warpage, such as orientation of polymer chains accompanying the flow of the resin, hardly occurs in the pressing process. Further, in the present pressing step and the previous coating step, the thermoplastic resin having a high viscosity is not forced to flow. As a result, it is possible to obtain a molded article having excellent optical characteristics such as low residual stress, low birefringence, and high light transmittance and high dimensional accuracy without warping as compared with the injection molding method of the prior art. Furthermore, the fine irregularities of the stamper 83 on the mold 81 are not easily destroyed, leading to a long life. Furthermore, since a strong pressing force is not required, it is possible to use a mold made of zinc selenide (ZnSe), silicon (Si) or the like which is not resistant to pressure.

  In addition, just before pressing, if a hot plate is inserted on the applied resin and the upper surface of the resin is heated to temporarily reduce the viscosity, the shape of the molded body can be adjusted at a lower pressure. it can. The heating plate may be one provided with an infrared lamp such as a halogen lamp, or a plate heated by a general electric heater or the like (resin is heated by radiant heat from the plate). Further, the pressing may be temporarily stopped immediately before the cavity surface of the upper mold comes into contact with the resin, and the press is performed after waiting for the temperature of the upper surface of the resin to rise due to the radiant heat from the cavity surface of the upper mold. Since these heating means are all radiant heat transfer, heat is transferred even in a vacuum. Therefore, even if the following pressure reduction / vacuum process is performed, heating can be performed without waste.

  Note that the precision force generator that can open and close the mold by moving at least one of the upper and lower molds and can perform clamping and pressing is realized by a vertical press machine, for example.

  In the decompression / vacuum process, which will be described later, it has a function of accurately detecting the position of the mold and temporarily stopping the mold closing operation with a minute gap between the upper mold cavity surface and the molten resin upper surface. preferable. Also, in the solidification process, the mold can be closed by an amount corresponding to the volume shrinkage of the molded body (highly accurate pressure control) while accurately following the set value to compensate the volume shrinkage of the molded body. It is preferable. Furthermore, in the following mold loosening step, it is necessary to slightly open the mold by a stroke smaller than the thickness of the molded body. Therefore, relatively high accuracy is required for positioning accuracy when moving the mold, speed control accuracy, and pressure control accuracy during mold clamping (pressing). Therefore, a force generator using a mechanism that easily ensures accuracy, such as a method of combining a servo motor and a ball screw as a drive system, is preferable.

  In the step (c), the upper mold 131 and the lower mold 132 are fitted to each other, and there is a minute gap between the cavity surface of the upper mold 131 and the upper surface of the thermoplastic resin. More preferably, after the air is sucked and reduced in pressure or substantially in a vacuum state, the cavity surface of the upper mold 131 and the upper surface of the thermoplastic resin are brought into contact with each other and a pressing force is applied. In this way, air between the melted thermoplastic resin and the cavity is eliminated, and transfer defects due to air entrainment / containment can be avoided.

  The air suction port may be specially provided on the cavity surface. However, for example, in the case of a mold having a mechanical ejector, the air suction port can be sucked from the cavity gap generated due to the sliding of the ejector. A known vacuum pump or the like may be used as the suction means. In this decompression and vacuum process, the upper and lower mold cavities have male and female shapes, and when the upper and lower molds are fitted in the mold closing process, a small amount of the male cavity enters the female cavity to form a closed space. More efficient when using a mold. The timing of depressurization and substantially vacuum is preferably after a small gap is formed between the upper mold cavity surface and the resin upper surface after forming the closed space. This is because after the cavity surface comes into contact with the resin and the air is confined, the suction effect cannot be obtained if there is no suction port in the confined range. In order to perform the decompression / vacuum process at an appropriate timing, for example, information on the mold position is obtained from a force generator, and when the desired position is reached, the suction means is activated, and the upper mold cavity surface is the top surface of the resin. What is necessary is just to stop a suction means in the position which touched completely. Also, starting of suction means → stopping mold closing → controlling with a timer, etc., and performing operations such as suction for a certain period of time → restarting mold closing, a means for detecting the pressure in the cavity is provided, and after the suction operation, desired Various forms of implementation are possible, such as resuming mold closing when the pressure is reduced to the pressure of.

  In the step (d), the molded body is cooled while a pressing force is applied until a desired temperature is reached, so that occurrence of defects such as sink marks due to resin volume shrinkage is prevented, and high-quality molding with high dimensional accuracy is achieved. You can get a body.

  In the step (e), even if the opening amount of the mold is large, the upper and lower molds can be kept in a fitted state, and preferably the depth (or height) of the fine uneven portion is small. The opening amount. For example, if the depth or (height) of the fine concavo-convex part is 50 μm, it can be opened by 50 μm or more and the molded body can be removed from the fine concavo-convex part.

  In the steps (f) to (i), examples of the peeling means mounted on the mold include a mechanical ejector mounted on the mold and an air blow mechanism, whereby the entire molded body is peeled from the cavity surface. Can do. If a small amount of peeled part is formed between the molded body and the cavity surface due to the pushing force of the mechanical ejector or the discharge pressure applied to the fluid discharged from the fluid discharge port, the fluid enters the part and the discharge pressure propagates there. Then, the next peeling is promoted, and the peeling portion is gradually enlarged. When this phenomenon occurs continuously, the entire molded body is peeled off from the cavity surface. Among the above, more preferably, a known air blow mechanism, that is, a discharge port for discharging a fluid such as air is provided in the cavity surface (preferably in the center of the molded body), and a mechanism for discharging the fluid from the discharge port is provided. It is preferable. In the mechanical ejector system, only a local part can be pushed (peeling force is applied). Therefore, when the thickness of the molded body is reduced, there arises a problem that the molded body is torn or broken before peeling occurs. With the method of feeding the gas to which the pressure is applied to the peeling portion as described above, the pressure acts on the entire peeling portion, and the peeling force can be generated uniformly, so that the thin molded body can be easily peeled off. Subsequently, the mold can be opened to such an extent that the molded body can be taken out, and the molded body can be taken out of the mold.

  According to the present invention, it is possible to obtain a thin-walled and large-area molded body having a thickness in the range of 50 μm to 5 mm and having a side length of the molded body exceeding 1000 times the thickness.

  Further, the fine uneven shape provided in the stamper 83 can be formed by using a semiconductor process such as a photolithography method, an electroforming method, or an ion etching method. Examples of the material of the stamper include nickel (or nickel alloy), silicon, glass, and the like. The stamper may be formed of only such a material, for example, a plate-like base material having a thickness of several tens of μm to several mm ( Fine irregularities may be formed with nickel on a silicon substrate. In the present invention, a fine uneven shape may be formed directly on the cavity surface of the lower mold body without using a stamper. The cross-sectional shape of the concavo-convex portion is basically rectangular, but may be a tapered (trapezoidal) shape, a triangular shape, a semicircular shape, a semielliptical shape, or the like.

There are various methods for heating and cooling the cavity surfaces of the upper and lower molds.
As the heating means, for example, the following method is used.
(1) A method in which a heat medium such as temperature-controlled water (hot water) or oil is circulated through a flow path of the medium provided in a mold and heated.
(2) A method in which an electric heater such as a plate heater or a cartridge heater is mounted on a mold and heated.
(3) A method in which infrared rays are irradiated on the surface of a mold cavity by a device that emits infrared rays, such as a halogen lamp and a far infrared heater, and heated.
(4) A method of induction heating.
(5) A method in which a thin conductive film is formed on the cavity body surface using the cavity body as an electrical insulator, and the conductive film is heated by energizing the conductive film.

Next, as a cooling means, for example, the following method is used.
(1) A method in which temperature-controlled water is circulated through a flow path of a medium provided in a mold and cooled.
(2) A method in which air is circulated through a pipe line provided in the mold and cooled.
(3) A method in which air or volatile (a phase change from liquid to gas at the cavity surface) and mist mixed with gas are sprayed on the cavity surface to cool it.
(4) A method of cooling by transporting and releasing the heat inside the mold out of the mold with a heat pipe.
(5) A method in which heat is taken from the inside of the mold or the cavity surface by an electric cooler such as a Peltier element.
What is necessary is just to use combining said heating and cooling means suitably.

  In the above, an example of using a storage cylinder that temporarily stores the molten resin that has flowed in and then sends out the specified amount is used. However, the present invention is not limited to this. For example, the cylinder having the injection function shown in FIG. The apparatus used as the delivery unit or the apparatus used as the resin delivery unit having the function of melting the thermoplastic resin shown in FIG. 6 and the injection function of injecting the molten resin in a specified amount may be used.

  Also, temperature control of resin melting section, resin delivery section, upper and lower molds, etc .; rotation and forward / backward movement control of screw, piston, etc. in resin melting section and resin delivery section; on connecting flow path between resin melting section and resin delivery section Control of opening and closing of the valve of the provided valve; control of the operation of moving the discharge unit to a desired position at a desired speed; control of vertical movement of the mold in the vertical direction, and the like are each performed by a control device (not shown).

  The molded body obtained by the present invention is a molded body having ultrafine processing, high dimensional accuracy, low residual stress, low birefringence, high light transmittance, and excellent mechanical strength, even in an ultra-low pressure molding process. For example, (a) microlens array, liquid crystal light guide plate, flexible display substrate, wave plate, reflector, retardation plate, free-form surface mirror, LED Key components in the field of electronic displays such as light-emitting panels and Fresnel lenses, (b) Optical information communications such as flexible polymer optical waveguides, free-form curved diffraction gratings, two-dimensional image sensor arrays, pickup lenses, holograms, and flexible waveguide illumination plates Core components in the field, (c) Next-generation DVD (Blu-ray Disc), Blu-ray Disc cover layer, DVD, CD, ultra-thin IC card and other optical recording media fields (D) key components in the life science field such as integrated chemical chips, DNA chips, biochips, protein chips, microfluidic devices, environmental analysis chips, (e) fuel cell separators, ultra-thin battery cases for mobile phones, It can be suitably used for key parts in the new energy field such as a sunlight collecting Fresnel lens.

It is typical sectional drawing for demonstrating the manufacturing apparatus of this invention. It is typical sectional drawing for demonstrating the storage cylinder used for this invention. It is a figure for demonstrating the form which the piston retracted in the storage cylinder used for this invention. It is typical sectional drawing of the manufacturing apparatus for demonstrating the form which provided the valve | bulb in the connection flow path between the resin melting part and the storage cylinder. It is typical sectional drawing for demonstrating another form of the manufacturing apparatus of this invention which used the cylinder which has an injection function as a resin delivery part. It is typical sectional drawing for demonstrating the manufacturing apparatus of another form of this invention. It is a figure for demonstrating the process of apply | coating molten resin to a to-be-coated surface from upper direction using a discharge part. (A), (b) is a figure for demonstrating the process of apply | coating molten resin from the discharge part which moves while being supported by a highly rigid guide. It is a figure for demonstrating an example of the means to move a lower metal mold | die to a perpendicular direction. It is a figure for demonstrating another example of the means to move a lower metal mold | die to a perpendicular direction. It is a figure for demonstrating another example of the means to move a lower metal mold | die to a perpendicular direction.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1, 2, 3 Manufacturing apparatus of this invention 10 Resin melting part 11,21 Resin delivery part 12 Discharge part 14 Connection flow path 15 Valve 81 Mold 83 Stamper 84 Tip lip part of discharge part 85 Molten thermoplastic resin 86 Molded object 91, 92, 911 Highly rigid guide 950 Bed 100 Press mold board 101 Cylinder 102, 211, 1111 Screw 103 Screw rotation mechanism 110 Storage cylinder 111, 1101 Cylinder 1102 Piston 1103 Piston drive means 1104 Gap 1106 Backflow prevention part 131 Upper mold 132 Lower mold 1001 Vertical movement stage

Claims (14)

A resin melting part that melts and transports a thermoplastic resin, a resin sending part that is connected to the resin melting part, sends a molten resin that flows in a specified amount, and a molten resin sent from the resin sending part. A discharge part that is applied to the surface to be coated from above, a high-rigidity guide that supports the discharge part, and a pair of molds that are arranged to face each other,
The resin delivery part is a storage cylinder that delivers a specified amount after temporarily storing the molten resin that has flowed in,
The storage cylinder includes a cylinder that stores molten resin, and a piston that is provided in the cylinder and that pushes out and sends out the molten resin in a specified amount, and the molten resin is interposed between the cylinder and the piston. There is a gap that can pass through,
The application surface of the molten resin is at least one part of the lower mold in the pair of molds, and the tip lip portion of the discharge part is moved along the shape of the application surface of the lower mold, Applying the molten resin to the application surface of the lower mold in a shape and thickness almost close to the final product,
Here, the discharge unit moves while being supported by a high-rigidity guide so as not to bend in the vertical direction due to the reaction of the application of the molten resin, and applies the molten resin,
Then, an apparatus for producing a formed feature that Ru obtain a molded body by pressure of molds,
A valve for opening and closing the connection channel is provided in the connection channel between the resin melting part and the resin delivery part; and
Further provided is a moving means for moving the application surface of the lower mold in the vertical direction so that the distance between the tip of the discharge part for applying the molten resin and the application surface of the lower mold can be adjusted. The manufacturing apparatus of the molded object characterized by becoming.   The said manufacturing apparatus is used in order to manufacture the molded object whose thickness is the range of 50 micrometers-5 mm, The manufacturing apparatus of the molded object of Claim 1 characterized by the above-mentioned.   The storage cylinder includes a cylinder for storing a molten resin, a piston that is provided in the cylinder and pushes out the molten resin by a specified amount, and a piston driving means for moving the piston back and forth, and the cylinder, A gap portion through which the molten resin can pass is provided between the piston and the piston is moved backward by the piston driving means together with the inflow of the molten resin from the resin melting portion, and a predetermined amount of the molten resin is supplied to the cylinder. 3. The molded body manufacturing apparatus according to claim 1, wherein the apparatus is configured such that a prescribed amount of molten resin is delivered by allowing the piston to move forward after being gradually stored from the front end portion.   The storage cylinder includes a cylinder for storing a molten resin, a piston that is provided in the cylinder and pushes out the molten resin by a specified amount, and a piston driving means for moving the piston back and forth, and the cylinder, A gap portion through which the molten resin can pass is provided between the piston and the piston is moved backward by the piston driving means to a place where a predetermined amount of the molten resin can be stored. And a predetermined amount of molten resin is gradually stored in the storage cylinder from the tip of the cylinder, and then the piston is advanced to deliver a specified amount of molten resin. The manufacturing apparatus of the molded object of Claim 1 or 2. Both sides of the discharge part are supported by at least two high-rigidity guides provided along the application direction of the molten resin, and the high-rigidity guides are upstream and downstream in the application direction of the molten resin. 5. The molded body manufacturing apparatus according to claim 1 , wherein the molded body manufacturing apparatus is fixed by two or more high-rigidity guide support members provided respectively. The manufacturing apparatus includes the resin melting part, a resin delivery part, a discharge part, a mold, and a bed on which these are mounted, and the discharge part applies the molten resin via a support member for the discharge part. The molded body according to any one of claims 1 to 4 , wherein the molded body is supported by at least one high-rigidity guide provided along a direction, and the high-rigidity guide is fixed to the bed. Manufacturing equipment. The moving means is a press mold plate for placing the lower mold and pressurizing both molds, and the vertical movement of the press mold plate moves the tip of the discharge portion and the lower mold cover. molded body manufacturing apparatus according to claim 1, wherein the distance between the application surface is adjusted. The moving means is a vertical movement stage provided between the lower mold and a press mold plate for placing the lower mold and pressurizing both molds, The apparatus for producing a molded body according to claim 1 , wherein the distance between the tip end portion of the discharge portion and the application surface of the lower mold is adjusted by vertical movement. A mold is placed on a lower mold, the mold is used as the coating surface, the lower mold and the mold are separable, and only the mold is moved up and down, and the discharge unit The apparatus for manufacturing a molded body according to claim 1 , wherein a distance between a front end portion and a surface to be coated on the lower mold is adjusted. A method of manufacturing a molded article using the manufacturing apparatus of the shaped body following the steps of heating at least one of (1) the pair of molds, the thermoplastic resin in (2) the resin melting portion A step of melting, (3) a step of allowing the obtained molten resin to flow into the resin delivery portion and storing, (4) a step of delivering the molten resin stored in the resin delivery portion in a specified amount, and (5) While moving the tip lip portion of the discharge portion along the shape of the surface to be coated of the lower mold, the molten resin sent to the surface to be coated of the lower mold has a shape and thickness substantially close to the final product. And (6) a step of cooling and solidifying the applied resin while pressing the applied resin to adjust the shape of the resin,
The resin delivery unit is a storage cylinder that temporarily stores the molten resin that has flowed in and then delivers the molten resin in a specified amount, and the storage cylinder is provided in the cylinder, and is provided in the cylinder and defines the molten resin. A piston that pushes out in an amount, and a gap portion through which the molten resin can pass is provided between the cylinder and the piston,
The method for producing a molded body, wherein the discharge unit moves while being supported by a high-rigidity guide so as not to bend in the vertical direction due to a reaction of the application of the molten resin.
Manufacturing equipment:
A resin melting part that melts and transports a thermoplastic resin, a resin sending part that is connected to the resin melting part, sends a molten resin that flows in a specified amount, and a molten resin sent from the resin sending part. A discharge part that is applied to the surface to be coated from above, a high-rigidity guide that supports the discharge part, and a pair of molds that are arranged to face each other,
The resin delivery part is a storage cylinder that delivers a specified amount after temporarily storing the molten resin that has flowed in,
The storage cylinder includes a cylinder that stores molten resin, and a piston that is provided in the cylinder and that pushes out and sends out the molten resin in a specified amount, and the molten resin is interposed between the cylinder and the piston. There is a gap that can pass through,
The application surface of the molten resin is at least one part of the lower mold in the pair of molds, and the tip lip portion of the discharge part is moved along the shape of the application surface of the lower mold, Applying the molten resin to the application surface of the lower mold in a shape and thickness almost close to the final product,
Here, the discharge part does not bend in the vertical direction due to the reaction of the application of the molten resin.
In addition, the molten resin is applied while being supported by a high-rigidity guide,
Thereafter, a molded body manufacturing apparatus characterized in that a molded body is obtained by pressing both molds. The storage cylinder includes a cylinder for storing a molten resin, a piston that is provided in the cylinder and pushes out the molten resin by a specified amount, and a piston driving means for moving the piston back and forth, and the cylinder, A gap portion through which the molten resin can pass is provided between the piston and the piston in the step (3), the piston is moved backward by the piston driving means together with the inflow of the molten resin from the resin melting portion. after slowly accumulating the molten resin quantitated from the tip portion of the cylinder, the (4) in the process, according to claim 10, characterized in that delivering a defined amount of the molten resin by advancing the piston Manufacturing method of a molded object. The storage cylinder includes a cylinder for storing a molten resin, a piston that is provided in the cylinder and pushes out the molten resin by a specified amount, and a piston driving means for moving the piston back and forth, and the cylinder, A gap portion through which the molten resin can pass is provided between the piston, and in the step (3), the piston is moved backward by the piston driving means to a place where a predetermined amount of the molten resin can be stored. After the molten resin is caused to flow from the resin melting portion and a predetermined amount of the molten resin is gradually stored from the tip of the cylinder in the storage cylinder, in the step (4), the piston is advanced to a specified amount. The method for producing a molded body according to claim 10 , wherein the molten resin is delivered. A valve that opens and closes the connection flow path is provided in a connection flow path between the resin melting part and the resin delivery part, and the valve is closed when the molten resin storage is completed in the step (3). The manufacturing method of the molded object in any one of Claims 11-12 . The method for producing a molded body according to any one of claims 11 to 13 , wherein in the step (5), the thickness of the molten resin applied to the surface to be coated is 50 µm to 5 mm.

Images